Replacing Your Hyundai Santa Fe's Fuel Cap: A Step-By-Step Guide

If you're looking to replace the fuel cap on your Hyundai Santa Fe, you've come to the right place. This article will outline the steps you need to take to replace the fuel cap on this vehicle. The fuel cap plays a crucial role in maintaining the efficiency, safety, and environmental friendliness of your car by preventing fuel vapour from escaping the fuel tank. A faulty fuel cap can cause issues with the vehicle's evaporative emission system, leading to increased emissions. Additionally, a leaking fuel cap can allow up to 30 gallons of gasoline to evaporate over a year, impacting fuel economy and the environment. To replace the fuel cap on your Hyundai Santa Fe, you can refer to the owner's manual or seek assistance from a qualified mechanic. You can also find compatible fuel caps for the Hyundai Santa Fe at automotive retailers, with options for both OEM and aftermarket parts.

How to open the fuel cap on different Hyundai Santa Fe models

To open the fuel cap on a Hyundai Santa Fe, the process differs depending on the model year of the car.

2005-2012 Model Years

For the 2005-2012 models, the gas cap can be opened from inside the car. There is a lever located on the driver's seat front floor area. To open the cap, pull the lever and then open the gas cap to refuel the car.

2013-2018 Model Years

For the third generation of the Hyundai Santa Fe, there is a button to open the fuel filler door located in the driver-side door. Simply pull this button and the fuel door will open.

2019-2021 Model Years

For the 2019-2021 models, there is no button or lever to open the fuel door. Instead, you must first unlock the car and get out of the vehicle. The fuel door is located on the driver's side of the car. To open it, push and release the centre-rear edge of the fuel door and it will pop open, allowing you to refuel. To open the fuel tank cap, turn it counterclockwise.

2014 Model

For the 2014 model, the gas tank latch is located in the door armrest.

The role of the fuel tank cap

The fuel tank cap is an essential component of your vehicle, with a vital role in maintaining fuel efficiency, preventing fuel contamination, and ensuring your safety. By creating a tight seal, the fuel cap prevents fuel vapour from escaping through the filler neck, reducing harmful emissions and fuel costs. This seal also stops contaminants, such as dirt, dust, and water, from entering the fuel system, which could cause engine damage and affect performance.

A properly functioning fuel cap also maintains the correct pressure in the fuel system, which is crucial for optimal fuel efficiency. Without a cap, extra air can enter the system, disrupting the air-fuel ratio and causing the engine to run less efficiently. This can also lead to an evap system leak and trigger the check engine light.

A damaged or missing fuel cap can cause a sudden decrease in fuel economy, so it is important to regularly inspect the cap for any signs of damage and to always tighten it securely after refuelling. This maintenance will ensure the longevity and optimal performance of your fuel tank cap, contributing to a greener and more efficient driving experience.

The fuel cap is, therefore, a critical component for the overall performance and safety of your vehicle.

Symptoms of a Diagnostic Trouble Code (DTC)

The Diagnostic Trouble Code (DTC) P0456 on a 2018 Hyundai Santa Fe indicates a very small leak in the evaporative emission system. This can be caused by a loose or leaking fuel tank cap, which is a crucial component in maintaining the efficiency, safety, and environmental friendliness of your vehicle. Here are some common symptoms and issues associated with this DTC:

• Malfunction Indicator Lamp (MIL) ON or flashing: The MIL lamp on your dashboard illuminates or flashes, indicating a potential issue with the evaporative emission system.
• Fuel odor in the vehicle: You may notice a fuel smell inside the car, suggesting a leak in the fuel system.
• Faulty fuel tank cap: The fuel tank cap may be faulty, cracked, or damaged, allowing fuel vapor to escape.
• Faulty Vapor Canister Purge Control Valve: The purge control valve may not be functioning properly, leading to issues with the evaporation system.
• Faulty Vapor Canister Close Valve: The canister close valve could be faulty, impacting the system's ability to maintain pressure and contain vapors.

To resolve the DTC P0456, it is recommended to inspect the fuel system, Canister Close Valve (CCV), and Evaporative Emissions (EVAP) Purge Control Valve (PCSV). If any issues are found, such as a faulty fuel tank cap, it should be replaced to correct the problem. This will help ensure the proper functioning of your Hyundai Santa Fe's fuel system and emission control.

How to inspect and diagnose a faulty fuel tank cap

To inspect and diagnose a faulty fuel tank cap, you can look out for the following signs:

• Check Engine Light: A broken or loose gas cap can trigger the Check Engine Light to come on as it affects the evap emissions system's pressure.
• Raw fuel smell: If you notice a strong smell of gasoline around your car, especially near the fuel filler area, it could be due to a damaged or improperly sealed gas cap.
• Poor fuel economy: A faulty gas cap may cause reduced fuel efficiency as it can allow fuel vapors to escape, leading to increased fuel consumption.
• Difficulty tightening or removing the gas cap: If you are having trouble tightening or removing the gas cap, it could be a sign that the threads or locking mechanism are damaged.

If you suspect a faulty fuel cap, you can perform the following diagnostic procedures:

Initial Inspection:

• Check for obvious mechanical signs such as torn inlet boots, missing or broken vacuum tees, and/or cracked, broken, or disconnected wire harnesses.
• Ensure all harness connectors are properly placed in the connectors and holders to prevent potential open or short-circuit issues.
• Inspect the connector for corrosion, frayed wiring, and damaged terminals.
• Always check for cracked or broken fuel hoses, vacuum lines, and pipes before attempting to diagnose EVAP leaks.

Diagnostic Procedures:

• Inspect the Fuel Tank Cap: Check the fuel cap for obvious signs of leakage and a cracked O-ring. If the O-ring is cracked, replace it and perform a repair validation. If the O-ring appears intact, proceed to the next step.
• Pressure Test: Use a fuel cap pressure test tool kit to apply pressure (approximately 2 PSI) and wait 10 seconds. If the pressure is held, the fuel tank cap is functioning properly. If the pressure drops, replace the fuel tank cap and perform a repair validation.
• Clear DTCs and Freeze Frame Data: After addressing the potential issues, clear the diagnostic trouble codes (DTCs) and freeze frame data.
• Drive Cycle: Perform the drive cycle requirements for the fault area and check for pending or stored DTCs. If no further issues are found, the repair is complete.

OEM and aftermarket gas cap products for the Hyundai Santa Fe

When it comes to replacing the fuel cap on your Hyundai Santa Fe, there are a variety of options available in the market, including both OEM and aftermarket products.

OEM Gas Caps

Hyundai Santa Fe gas caps are available from a variety of online retailers, including HyundaiPartsDeal and Amazon. These gas caps are designed to fit specific Hyundai Santa Fe models, so it is important to select the correct part number for your vehicle. The part number can be found on the HyundaiPartsDeal website by selecting your vehicle's model or VIN.

For example, the part number 31010-38200 is listed as fitting the 2000-2006 Hyundai Santa Fe High Grade and Middle Grade 5 Door Wagon. This gas cap is available for $14.19, a savings of 24%genuine Hyundai part and is guaranteed by Hyundai's factory warranty.

Another option is the part number 31010-R5000, which fits the 2021-2023 Hyundai Santa Fe with the DOHC - GDI or DOHC - TCI/GDI engine and the 5Door 5P body style. This gas cap is also available for a discounted price of $35.99, a savings of 29%backed by Hyundai's factory warranty.

Aftermarket Gas Caps

In addition to OEM parts, there are also aftermarket gas caps available for the Hyundai Santa Fe. These products are manufactured by third-party companies and are designed to fit multiple vehicle makes and models.

One example is the Replacement Fuel Tank Gas Cap sold by AA Ignition on Amazon. This gas cap is compatible with a wide range of Hyundai vehicles, including the Santa Fe, Sonata, Tucson, and others. It is a direct replacement for the OEM part and is designed to prevent gas or diesel vapors from escaping while the vehicle is in operation. This gas cap is available for $10.98 and comes with a lifetime warranty from AA Ignition.

Another option for an aftermarket gas cap is the Carquest Premium Fuel Cap, which can be found at Advance Auto Parts. There are multiple Carquest Premium Fuel Caps available, with different types of closures, including twist-lock and screw-on. These fuel caps are manufactured with OEM quality materials and safety standards and are designed to pass all state and federal emissions requirements. They are also designed with specific pressure and vacuum relief valves to prevent fuel evaporation. The price of these fuel caps starts at $14.99.

Frequently asked questions